Pulse-On-Pulse (Gmaw-Pp - Lincoln Electric POWER WAVE 355/405 SVM159-A Service Manual

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PULSE-ON-PULSE™ (GMAW-PP)
Pulse on Pulse™ is a Lincoln process specifically
designed for use in welding relatively thin (less than
1/4" thick) aluminum (See the table below). It gives
weld beads with very consistent uniform ripple.
In Pulse on Pulse modes, two distinct pulse types are
used, instead of the single pulse type normally used in
GMAW-P. A number of high energy pulses are used to
obtain spray transfer and transfer metal across the arc.
Such pulses are shown in the figure below. After a
number "N" of such pulses, depending on the wire feed
speed used, an identical number "N" of low energy
pulses are performed. These low energy pulses,
shown in the figure below, do not transfer any filler
metal across the arc and help to cool the arc and keep
the heat input low.
"N" PULSES
HIGH HEAT
PULSES
PEAK
AMPS
BACKGROUND
AMPS
The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down,
the major effect of the low energy pulses is that they
form a weld ripple. Since they occur at very regular
time intervals, the weld bead obtained is very uniform
with a very consistent ripple pattern. In fact, the bead
has its best appearance if no oscillation of the welding
gun ("whipping") is used.(See the figure below)
MATERIAL
WIRE SIZE
COMMENTS
INSTALLATION
"N" PULSES
LOW HEAT
PULSES
TIME
WELDING PROCEDURES FOR PULSE-ON-PULSE
Aluminum 4043 Aluminum 4043
GAS 100% Ar.
WIRE E4043
0.035
14 ga. 250 / 0
10 ga. 400 / 0
3/16 550 / 0
1/4 600 / 0
Not Recommended Not Recommended
below 200 WFS below 100 WFS
POWER WAVE 355
When Arc Control is used in the Pulse on Pulse modes,
it does the same things it does in the other pulsed
modes: decreasing the Arc Control decreases the
droplet transfer and weld deposition rate. Increasing
the Arc Control increases the droplet transfer and weld
deposition rate. Since Arc Control varies weld droplet
transfer rate, the Arc Control can be used to vary the
ripple spacing in the weld bead.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
Table B.2 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position. The val-
ues in the table can be helpful as a starting point to
establish a welding procedure. From there, adjust-
ments need to be made to set the proper procedure for
each specific application (out-of-position, other types
of joints, etc.).
The comments on the table below show values of WFS
below which it is not recommended to weld. The rea-
son is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.
Aluminum 5356
100% Ar. 100% Ar.
E4043 E5356
3/64 0.035
200 / 0 230 / 0
280 / 0 425 / 0
340 / 0 670 / 0
400 / 0 700 / 0
Not Recommended Not Recommended
below 200 WFS
Aluminum 5356
100% Ar.
E5356
3/64
225 / 0
400 / 0
500 / 0
550 / 0
below 200 WFS
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